TWI586506B - Fiber sheet and method for producing the same - Google Patents

Description

Fiber sheet and method of manufacturing same

The invention discloses a fiber sheet and a method of manufacturing the same. More specifically, the present invention discloses a fiber sheet having fibrous particles and a method of producing the same.

In the past, a fiber granule was known which was formed by granulating fibers. Fiber particles are also known as fiber balls. Fiber balls can be used for cushions and the like. For example, Japanese Laid-Open Patent Publication No. Hei 3-45134 (hereinafter referred to as Patent Document 1) discloses a mattress in which a fiber ball is filled in a cover.

However, in the mattress of Patent Document 1, since the fiber ball moves in the outer cover, the fiber ball may be concentrated and the like, and sufficient cushioning properties may not be obtained. Further, since the fiber ball is a small particle, it is difficult to handle without being filled in a cover or the like, and its use is limited.

It is an object of the present invention to provide a novel material using fibrous particles.

The fiber sheet of the present invention comprises a plurality of fiber particles which are formed by fiber interlacing. The plurality of fiber particles are entangled in a three-dimensional manner by fibers protruding toward the periphery. The plurality of fiber particles are bonded by heat-fusible fibers contained in the plurality of fiber particles.

A method for producing a fiber sheet according to the present invention, comprising the steps of: interlacing fibers into granules to form a plurality of fiber granules; and arranging the plurality of fiber granules in a three-dimensional manner to form a flaky shape; The fiber pellets arranged in a three-dimensional manner are heated, and the plurality of fiber pellets are bonded by the heat-fusible fibers contained in the plurality of fiber pellets.

Since the fiber sheet of the present invention has fiber particles, it is excellent in elasticity and has high cushioning properties. Since the fiber sheet of the present invention can hold air, it is excellent in heat insulation. The fiber sheet of the present invention is a sheet having fiber granules, and can be applied not only as a bedding material or a clothing material but also as a mat for a transportation tool or a substrate in a medical or agricultural field. In the method for producing a fiber sheet of the present invention, it is possible to easily produce a fiber sheet having fiber particles.

1‧‧‧Fiber flakes

1B‧‧‧ slab fiber flakes

1R‧‧‧Roller-shaped fiber flakes

2, 2p, 2q, 2r, 2s‧‧‧ fiber

2A‧‧‧Grain

2B‧‧‧Mous

2P‧‧‧ Core Department

2Q‧‧‧External Department

2S‧‧‧Flake granules

3, 3a‧‧‧ fiber

10‧‧‧Original cotton

11‧‧‧Fiber mixing device

12, 12A, 12B‧‧‧ fiber particle forming device

13, 13A, 13B‧‧‧ Included Tower

14, 50‧‧‧Fiber particle arranging device

15‧‧‧Configuration container

16‧‧‧ gap

17, 17a, 17b, 21‧‧ ‧ rolls

18, 57‧‧‧ 容 部

19‧‧‧ inclined section

20‧‧‧ heating device

51‧‧‧Supply conduit

52‧‧‧Exhaust duct

53‧‧‧Reservation Department

54‧‧‧Upper air outlet

55‧‧‧Supply roller

55a‧‧‧Scrapping Department

56‧‧‧Distribution roller

56a‧‧‧ protruding stick

58‧‧‧Lower air outlet

59‧‧‧Internal air passage

60‧‧‧Out of the roll

61‧‧‧Out of the board

62‧‧‧fan

63‧‧‧Control Department

64‧‧‧Import and Export Department

65‧‧‧pressure sensor

66‧‧‧Sheet width adjuster

66a‧‧‧Sheet width adjustment department

Fig. 1 is a schematic view showing an example of a fiber sheet; Fig. 1 is a view of Fig. 1A and Fig. 1B, Fig. 1A is a perspective view, and Fig. 1B is an enlarged cross-sectional view.

Fig. 2 is a schematic front view showing an example of fiber particles.

Fig. 3 is a schematic view showing an example of a method for producing a fiber sheet.

Fig. 4 is a schematic configuration diagram showing an example of a fiber particle arranging device; Fig. 4 is a view showing a fourth drawing and a fourth drawing, Fig. 4A is a side view, and Fig. 4B is a front view.

Fig. 5 is a view of Fig. 5A and Fig. 5B; Fig. 5A is a photograph of an example of a fiber particle, and Fig. 5B is a photograph of an example of a fiber sheet.

Fig. 6 is a graph showing the standard deviation of the gray scale values of the particle examples of the four types of fiber particles.

Fig. 7 is a photograph of an example of fiber particles of different types; Fig. 7 is composed of Fig. 7A to Fig. 7D, Fig. 7A shows fiber particles (2p) of the particle example 1, and Fig. 7B shows particle case 2 Fibrous granules (2q), Fig. 7C shows granules (2r) of granule example 3, and Fig. 7D shows granules (2s) of granule example 4.

Fig. 1 schematically shows an example of the fiber sheet 1. Fig. 1 is composed of Fig. 1A and Fig. 1B. As can be seen from Fig. 1, a plurality of fiber particles 2 are present in the fiber sheet 1. Fig. 2 is a view schematically showing an example of the fiber particles 2 used in the fiber sheet 1. 1 and 2 are schematically represented in an easily understandable manner, and the physical object may be different from the aspect represented by the drawings.

As shown in FIG. 1A, the fiber sheet 1 has a plurality of fiber particles 2. As shown in Fig. 1B, the fiber particles 2 are formed by interlacing the fibers 3. The plurality of fiber particles 2 are intertwined in a three-dimensional manner by the fibers 3a protruding toward the periphery. The plurality of fiber particles 2 are heat contained in the plurality of fiber particles 2 Fusion fibers to bond. The fiber sheet 1 is provided with the fiber particles 2, and therefore has excellent elasticity and high cushioning property. The fiber sheet 1 is capable of retaining air and is therefore excellent in heat insulation. The fiber sheet 1 is a sheet having the fiber particles 2, and can be used not only as a bedding or a cloth but also as a mat for a transportation tool or a substrate in a medical or agricultural field.

As shown in Fig. 2, the fiber particles 2 are composed of a plurality of fibers 3. It is the fiber particle 2 which is entangled by the plural fiber 3 and becomes granular. A part of the fiber 3 protrudes from the fiber particle 2 toward the periphery. The fiber 3 protruding toward the periphery is defined as the fiber 3a. The ends of the fibers 3a may be disposed outside the agglomerates of the fiber particles 2. By having the fibers 3a, the plurality of fiber particles 2 can be bonded while being maintained in the state of the particles.

The fiber particles 2 are preferably approximately spherical. Thereby, the fiber pellets 2 can be easily arranged more uniformly in a three-dimensional manner. The approximate spherical shape may be a shape that is circular when viewed by the naked eye. The fibrous particles 2 may be circular without angulation.

The average particle diameter of the fiber particles 2 is preferably in the range of 1 to 50 mm. Thereby, the elasticity can be improved. The average particle diameter of the fiber particles 2 is more preferably in the range of 2 to 30 mm, further preferably in the range of 2 to 20 mm, and still more preferably in the range of 3 to 10 mm. Further, the average particle diameter was measured on the basis of a portion in which the fibers excluding the protruding fibers 3a were gathered into a circular portion. The average particle diameter is obtained by measuring and averaging the size of a specific number (for example, 100 or the like) of the fiber particles 2. The so-called actual measurement may be a measurement performed by a measuring instrument or the like. At this time, the size can be measured using a photograph.

The fibrous particles 2 have an air layer in the particles. Since the plural fibers 3 are intertwined in a three-dimensional manner, air is present in the gaps of the fibers 3. Therefore, the elasticity can be improved. Moreover, since the air is retained, the fiber sheet 1 can be given a unique and comfortable texture. Also, since the fiber particles 2 retain air, they are light. Further, since the fiber particles 2 are particles, they are bulky and have high durability. Further, the fiber particles 2 have moisture retention properties. Further, the fiber particles 2 are excellent in fluidity.

As the fiber 3, any of synthetic fiber and natural fiber can be used. Examples of the synthetic fiber include polyester fiber, polyolefin fiber, acrylic fiber, polyamide fiber, cellulose fiber, and polyphenylene sulfide fiber (PPS). The fiber 3 is preferably a polyester fiber. By using a polyester fiber, the fiber sheet 1 excellent in elasticity can be easily formed. Examples of the polyester include polyethylene terephthalate (PET) and polyethylene naphthalate fiber (PEN). As the natural fiber, wool can be exemplified. The fiber particles 2 and the fiber sheet 1 formed of wool have high heat insulating properties. Further, the fiber sheet 1 of wool can impart a comfortable texture. Further, as the fiber 3, a mixed fiber can also be used. The blended fibers were obtained as a cotton blend. Functionality can be improved by using a blend. For example, the fiber sheet 1 having deodorizing property can be easily formed by blending containing acrylic fibers. Moreover, the elasticity and the like can be adjusted by using the blending. Wool and synthetic fibers can be mixed. As the fiber 3, a fiber which is hollow inside can also be used. Thereby, the elasticity can be further improved.

The fiber 2 contains heat-fusible fibers. By including the heat-fusible fiber, the fiber particles 2 can be easily bonded. Heat-fusible fiber is made It functions as a binder. The ratio of the heat-fusible fibers in the entire fiber 3 is preferably in the range of 0.1 to 50% by mass. Thereby, the elasticity can be maintained and the adhesion can be improved. The ratio of the heat-fusible fibers in the entire fiber 3 is more preferably in the range of 1 to 40% by mass. The fibers 3 constituting the fiber particles 2 may include heat-fusible fibers and fibers which are not thermally welded or which are not easily heat-sealed. Further, as long as the performance of the fiber sheet 1 can be ensured, the fiber particles 2 may be formed entirely of heat-fusible fibers.

The fiber particles 2 preferably contain two or more kinds of polyester fibers having different melting points. The plurality of polyester fibers are classified into a high melting point polyester fiber and a low melting point polyester fiber. The melting point of the high melting point polyester fiber is higher than the melting point of the low melting point polyester fiber. A low-melting polyester fiber can be a heat-fusible fiber. By making the heat-fusible fiber a low melting point, it is easy to obtain a high-strength adhesiveness. The melting point of the heat-fusible polyester fiber may be, for example, in the range of 100 to 160 °C. Thereby, the bonding is easier. The melting point of the low melting point polyester fiber may be, for example, in the range of 110 to 150 °C. The melting point of the high melting point polyester fiber may be, for example, 10 ° C or more higher than the melting point of the low melting point polyester fiber. Thereby, the formability is improved. The melting point of the high melting point polyester fiber may be, for example, in the range of 130 to 300 °C. The melting point of the high melting point polyester fiber may also be, for example, in the range of 150 to 250 °C.

The fibers 3 are preferably short fibers. If the fiber 3 is a short fiber, the fiber particle 2 is easily formed. The fiber length of the fiber 3 is preferably in the range of 2 to 100 mm. By using the fibers 3 of the length of this range, it is possible to impart good elasticity. Fiber length of fiber 3 is better at 3~ Further preferably, it is in the range of 5 to 50 mm in the range of 80 mm. The thickness (fineness) of the fiber 3 is preferably in the range of 1 to 40 denier. By using the fiber 3 of this range, it is possible to impart good elasticity. Danny is the unit that represents the quality of the 9000-meter yarn in grams. The measured diameter of the fiber 3 may be, for example, in the range of 10 to 200 μm, but is not limited thereto. Micro-sized fibers are called microfibers. High functionality can be imparted by using microfibers.

The fibers 3 are preferably coated with a crucible. If the fiber 3 is covered with ruthenium, the slipperiness of the fiber 3 is improved, and the fiber 3 is easily entangled into a granular shape. Therefore, the fiber sheet 1 can be easily manufactured. The amount of sputum used to cover the mites can be trace amounts. For example, when the amount of the fiber is 100 parts by mass, the amount of cerium may be 0.0001 to 1 part by mass. By making the amount of ruthenium into this range, the interlacing property of the fiber is improved.

The fiber particles 2 preferably have a core portion which is closely intertwined by the fibers 3. In the core portion, the fibers 3 are arranged in a compact manner, and thus the proportion of the fibers 3 is large. Around the core is a peripheral portion that has a smaller proportion of fibers than the core. By having the core portion, the particles of the fiber particle 2 can be made firm and not easily broken. The core portion 2P and the peripheral portion 2Q are shown in Fig. 2 . Further, the fibers 3 can be uniformly present in the fiber particles 2.

As shown in Fig. 1, in the fiber sheet 1, the fiber particles 2 maintain the state of the particles to a certain extent, and the fiber particles 2 are adhered by the fibers 3a protruding toward the periphery. The fiber sheet 1 includes a granular portion 2A formed of the fibrous particles 2, and a fibrous portion 2B disposed on the periphery of the granular portion 2A. Wai. In Fig. 1A, although the fiber particles 2 are drawn in a circular shape in such a manner that the structure is easily understood, the fiber particles 2 may be agglomerates of the fibers 3. The portion formed by the fiber particles 2 becomes the granular portion 2A. Further, in Fig. 1A, although the fibers 2 are drawn as blanks in such a manner that the structure can be easily understood, it can be seen from Fig. 1B that the fibers 3a protruding from the fiber particles 2 between the fiber particles 2 are mutually The fibers 2 are entangled and bonded to thereby fix the fiber particles 2. The portion between the fiber particles 2 becomes the wool portion 2B.

In the fiber sheet 1, the fiber particles 2 are not individually granulated, and the fiber granules 2 are bonded to the other fiber granules 2 disposed around. In the granular portion 2A, the fibers 3 are rounded and entangled. In the spline portion 2B, the fibers 3 are not gathered into a circular shape and are intertwined into a non-fixed shape. The cotton portion 2B is in the form of a cotton. The amount of fibers in the granular portion 2A is larger than the amount of fibers in the wool portion 2. For example, when the object on the back side of the sheet is observed through the fiber sheet 1, the visibility of the cotton portion 2B can be higher than that of the granular portion 2A. If it is the weaving part 2B, it can pass through and can see an object. The fibers 3 intertwined in the mushy portion 2B are bonded by heat-fusible fibers. Therefore, the granular portion 2A and the cotton portion 2B are in close contact with each other, and the fiber particles 2 are prevented from being detached from the fiber sheet 1. Thereby, the fiber sheet 1 with high adhesiveness and excellent strength can be obtained. The fiber 3a protruding from one of the fiber particles 2 can intrude into the other fiber particle 2. Thereby, the adhesion is further improved. Within the fiber particles 2, the fibers 3 can be bonded by heat-fusible fibers. Thereby, the strength can be increased.

Since the fiber sheet 1 has the granular portion 2A and the wool portion 2B, it has a characteristic elasticity. The elasticity of the fiber sheet 1 can be exhibited when a force for deforming the fiber sheet 1 is applied. For example, in the fiber sheet 1 will not break When the force of the degree of damage is used to stretch the fiber sheet 1 in the direction of expansion, the amount of expansion of the cotton portion 2B is larger than that of the granular portion 2A. Further, when the fiber sheet 1 is crushed, the amount of shrinkage of the wool portion 2B is larger than that of the granular portion 2A. In this way, the amount of expansion and contraction is made different by having the granular portion 2A and the cotton portion 2B. Therefore, it is possible to impart excellent elasticity.

In the fiber sheet 1, it is preferable that the granular portion 2A (i.e., the fiber particles 2) is present in the fiber sheet 1 in an approximately equal amount. For example, when a sample having a size of 100 mm × 100 mm is cut out from the fiber sheet 1, it is preferable that the number of the granular portions 2A (that is, the fiber particles 2) contained in the sample is approximately the same amount. In the plural sample, the number of the granular portions 2A contained in the sample may fall within the range of ±10% of the average value. The ratio of the number of the fiber particles 2 in the fiber sheet 1 is, for example, 10 to 100,000 sheets (referred to as "unit sheets") having a length of 100 mm, a width of 100 mm, and a thickness of 10 mm. Thereby, an excellent elastic force can be imparted. The ratio of the number of the fiber particles 2 in the fiber sheet 1 is, for example, preferably from 100 to 10,000, more preferably from 200 to 1,000, per unit of the sheet.

The thickness of the fiber sheet 1 is preferably in the range of 5 to 100 mm. Thereby, the fiber sheet 1 is easily handled. The thickness of the fiber sheet 1 is more preferably in the range of 10 to 50 mm. The fiber sheet 1 is preferably 300 mm in length × 300 mm in width or more, more preferably 500 mm in length × 500 mm in width or more. In the case of the fiber sheet 1, excellent elasticity can be obtained even when it becomes large. Further, the thickness of the fiber sheet 1 is larger than the size of the fiber particles 2.

The mass per unit area of the fiber sheet 1 can be appropriately changed depending on the application. In the fiber sheet 1, the mass per unit area can be adjusted by adjusting the density of the fiber particles 2. The mass per unit area of the fiber sheet 1 can be set, for example, in the range of 10 to 10,000 g/m ² . Since the fiber sheet 1 contains air, it can be lightweight. Therefore, the operability of the fiber sheet 1 can be improved. The gas permeability of the fiber sheet 1 can be appropriately changed depending on the use. In the fiber sheet 1, the air permeability can be adjusted by adjusting the density of the fibers 3. The gas permeability of the fiber sheet 1 (the amount of air passing through an area of 1 cm ^{2 in} one second when a fixed pressure is applied to the sheet) can be set, for example, in the range of 1 to 500 cm ³ /cm ² ‧ s. In particular, when the gas permeability of the fiber sheet 1 is 5 cm ³ /cm ² ‧ s or less, it is possible to provide a sheet having less gas permeability. Further, for example, when the gas permeability of the fiber sheet 1 is 50 cm ³ /cm ² ‧ s or more, a sheet having high gas permeability can be provided. Moreover, if an air layer can be formed in the fiber sheet 1, heat insulation can be improved. The gas permeability of the fiber sheet 1 can be measured by a Frazier type gas permeability tester. It is preferable that the fiber sheet 1 is pressed in the thickness direction to compress the thickness to 50%, and then, when the compressive force is released, it is possible to return to the original thickness. Thereby, the fiber sheet 1 excellent in elasticity can be obtained. The tensile strength of the fiber sheet 1 can be appropriately changed depending on the use. In the fiber sheet 1, the tensile strength can be adjusted depending on the kind or amount of the heat-fusible fiber. The tensile strength of the fiber sheet 1 can be set, for example, in the range of 1 to 1000 N/5 cm. If the tensile strength is high, it is possible to suppress the fiber sheet 1 from being broken or the fiber particles 2 from falling off, and to obtain the fiber sheet 1 having higher strength.

The fiber sheet 1 can be formed into a long shape. The fiber sheet 1 can also be formed by winding. When the fiber sheet 1 can be wound, the manufacturability can be improved. When the long shape is formed, the width (length in the short side direction) of the fiber sheet 1 is, for example, preferably 500 mm or more, and more preferably 100 mm or more. The width of the fiber sheet 1 may be, for example, 3,000 mm or less. Thereby, the fiber sheet 1 can be easily manufactured.

The fiber sheet 1 has an air layer in the granular portion 2A and the wool portion 2B. Since the plural fibers 3 are intertwined in a three-dimensional manner, air is present in the gap of the fiber sheet 1. Therefore, it will increase the flexibility. Further, since the amount of the fibers 3 is different between the granular portion 2A and the wool portion 2B, it is possible to impart unique elasticity. Further, since the granular portion 2A and the cotton portion 2B retain air, the fiber sheet 1 can obtain a unique and comfortable texture. For example, a tactile sensation like feathers can be obtained. Further, the fiber sheet 1 is light, has a bulkiness, and has high durability. Further, the fiber sheet 1 has moisture retention properties. Further, in the fiber sheet 1, since the fiber particles 2 are bonded, the fiber particles 2 do not concentrate on one side, and thus the shape retention is excellent.

The fiber sheet 1 has high pressure dispersion resistance. Since the fiber particles 2 are subjected to pressure, and the entangled portion of the fibers 3 between the fiber particles 2 absorbs the pressure, the pressure-resistant dispersibility of the fiber sheet 1 is more than that of the sheet which is only intertwined by the fibers in a three-dimensional manner. high. Therefore, the fiber sheet 1 is excellent as a material of a bedding or a cushion. The fiber sheet 1 has a raised portion while having excellent elasticity. The fiber sheet 1 is formed by firmly bonding the fiber particles 2. Moreover, the fiber sheet 1 easily returns to the original even if it collapses. shape. Further, the fiber sheet 1 is excellent in drying property. Therefore, washing can be performed in a household washing machine.

A method of producing the fiber sheet 1 will be described.

The method for producing the fiber sheet 1 comprises the following steps.

‧ The fibers 3 are intertwined into a granular shape to form a plurality of fiber particles 2; ‧ a plurality of fiber particles 2 are arranged in a three-dimensional manner to form a sheet shape; ‧ a plurality of fiber particles 2 arranged in a three-dimensional manner are heated Further, the plurality of fiber particles 2 are bonded by the heat-fusible fibers contained in the plurality of fiber particles 2.

In the method for producing the fiber sheet 1, the fiber sheet 1 having the excellent characteristics described above can be easily produced. Further, it is possible to produce the fiber sheet 1 efficiently.

In the method for producing the fiber sheet 1, when the plurality of fiber particles 2 are three-dimensionally arranged to form a sheet shape, the following steps are preferably included.

‧ accommodating a plurality of fiber particles 2; ‧ output a plurality of fiber particles 2 from the gap 16 .

Fig. 3 is a schematic view showing an example of a method of producing the fiber sheet 1. Hereinafter, the manufacturing method will be described in more detail based on Fig. 3 . In Fig. 3, the flow of the steps is indicated by a blank arrow. Further, the flow of the fiber 3 is indicated by a solid solid arrow. Moreover, the state in the container is appropriately drawn so that the fiber 3 and the fiber particle 2 can be easily understood.

In the manufacturing process of the fiber sheet 1, the raw cotton 10 is first prepared. The original cotton refers to cotton as a raw material. If it is a chemical synthetic fiber, If the synthesized fiber is in the form of a cotton, it becomes the original cotton. The fibers constituting the primary cotton 10 may be short fibers. Also, the original cotton 10 is opened. By opening the fiber, the entangled fibers can be unwound. When the fiber bundle is formed, the fibers can be separated by opening the fiber. However, the fibers may not be completely dispersed. As long as a certain degree of fiber development is progressed, you can proceed to the next step. The separated fibers 3 may be in a state of being swollen.

Here, as the primary cotton 10, the main raw cotton 10 and the secondary raw cotton 10 can be prepared. The main raw cotton 10 is the main fiber 3 used to constitute the fiber sheet 1. The main raw cotton 10 can have more fiber than the primary one. The secondary raw cotton 10 can be composed of heat-fusible fibers. The main raw cotton 10 can be composed of fibers that are not thermally welded or heat-weldable. Further, the fiber 3 obtained by opening the main raw cotton 10 and the fiber 3 obtained by opening the secondary raw cotton 10 may be mixed. These fibers 3 are preferably mixed approximately uniformly. Thereby, the heat-fusible fiber can be blended into the fiber 3 in an appropriate amount. A cotton obtained by mixing a plurality of kinds of fibers 3 is called a blend. Further, as the primary cotton 10, an original cotton in which heat-fusible fibers are mixed in advance may be used. At this time, the operation of mixing the fibers can be omitted. Further, the pre-opened heat-fusible fiber can be blended without using the secondary raw cotton.

A specific primary cotton 10 can be used, which comprises a fiber 3 coated with enamel. The crucible is attached to the surface of the fiber 3. If the fiber 3 is covered by enamel, the operability of the fiber 3 is improved. When the raw cotton 10 formed of the fiber which has been previously coated with ruthenium is used, the efficiency is improved. Further, the crucible can be attached to the opened fiber 3. When using liquid helium, 矽 矽 ,, to make the 矽 attach. At this time, when the fiber 3 is sprayed while stirring the fiber 3, the flaw can be more uniformly adhered. As a crucible, eucalyptus oil can be used.

The mixing of the fibers 3 can be carried out by the fiber mixing device 11. The fiber mixing device 11 is a device for mixing the fibers 3 by stirring. Mixing can be carried out by the fiber mixing device 11. Stirring can be carried out by agitating the blades or by air flow. Further, the mixing of the crucibles performed as needed may be carried out using the fiber mixing device 11.

The fiber 3 is conveyed to the fiber particle forming device 12. Since the fiber 6 that has been opened is light, it can be transported by an air stream. The devices from the fiber mixing device 11 to the fiber arranging device 14 can be connected by a pipe which feeds the fibers 3 by air flow.

In the example of FIG. 3, the fiber particle forming apparatus 12 is provided with two fiber particle forming apparatuses 12. The fiber particle forming device 12 is defined as the first fiber particle forming device 12A and the second fiber particle forming device 12B in the order in which the fibers 3 flow. The fibrous particle forming device 12 has a truncated conical container. In a truncated conical container, air will rotate and flow. The air can rotate in a spiral. The air can flow in a whirlwind. The fiber 3 enters from above the fiber particle forming device 12. Further, the fibers 3 conveyed along the air flow are rotated in a three-dimensional manner as the air in the fiber particle forming device 12 rotates, and are rounded to become granular. The fiber 3 can become approximately spherical. In the container, the agitating blades are rotatable. The fiber particle forming device 12 is capable of causing air convection. The fiber 3 moved from above to below can be moved to the top several times. The fibers 3 are easily rounded by being subjected to resistance. fiber 3 can collide with the wall of the container. As a result, the fibers 3 emerging from the fiber particle forming device 12 become the fiber particles 2. The fiber particles 2 are taken out from the lower side of the fiber particle forming device 12.

The fiber particles 2 emerging from the fiber particle forming device 12 are preferably: the receiving tower 13 temporarily entering the storage fiber particles 2. In the accommodating tower 13, the fiber granules 2 are stacked in the vertical direction and temporarily accommodated. The accommodating tower 13 serves as a granule tank. In this way, by storing the fiber particles 2, the fiber particles 2 can be transported to the next device in a stable amount. Therefore, it is possible to form a good fiber sheet 1 in which the particles of the fibers are aligned. The fiber pellet 2 enters the accommodating tower 13 from the upper portion of the accommodating tower. The fiber particles 2 are taken out from the accommodating tower 13 at the lower portion of the accommodating tower. In the accommodating tower 13, the fiber granules 2 enter from the upper portion, and at the same time, the fiber granules 2 are discharged from the lower portion, and thus the fiber granules 2 are constantly accumulated and exist. The accommodating tower 13 serves as a reservoir.

In the example of Fig. 3, the first accommodating tower 13A and the second accommodating tower 13B are provided. The first accommodating tower 13A is provided between the first granule forming apparatus 12A and the second granule forming apparatus 12B. The second accommodating tower 13B is provided between the second granule forming apparatus 12B and the granule arranging device 14. By the presence of the first accommodating tower 13A, the amount of the fiber granules 2 sent to the second granule forming apparatus 12B can be stabilized. By the presence of the second accommodating tower 13B, the amount of the fiber granules 2 sent to the fiber arranging device 14 can be stabilized.

Here, when a plurality of the fiber particle forming apparatuses 12 are passed, the fibers 3 are easily aggregated. Therefore, in the example of Fig. 3, in order to obtain the fiber pellets 2 having the neat shape, two fiber pellet forming apparatuses 12 are used. First The fiber particle forming device 12A makes the core of the fiber particle 2 easy to manufacture. In the first fiber particle forming apparatus 12A, the dispersed fibers 3 can be rounded to form the fiber particles 2. The fiber particles 2 can be formed by interlacing the fibers 3. However, the fiber particles 2 emerging from the first fiber particle forming device 12A may be fiber particles which are soft and have no surrounding appearance. Therefore, the second fiber particle forming device 12B further applies resistance to the fiber particles 2 to tighten the fiber particles 2. The second fiber granule forming apparatus 12B can make the entanglement of the fibers 3 in the fiber granules 2 strong. The fiber 3 can be collected by the second fiber particle forming device 12B. The fiber particles 2 are made firm by strongly tightening the fibers in the fiber particles 2. The fiber particles 2 from the second fiber particle forming device 12B are stronger than the fiber particles 2 before entering the second fiber particle forming device 12B. The fiber particles 2 can be hard. The density of the fiber particles 2 can be made large. The fiber interlacing condition in the fiber particles 2 can be increased. The particle diameter of the fiber particles 2 can be made small. The density of the fiber particles 2 from the second fiber particle forming device 12B may be, for example, 1.5 to 5 times as compared with the density of the fiber particles 2 before entering the second fiber particle forming device 12B. The elasticity of the fiber particles 2 can be improved by using a plurality of fiber particle forming devices 12. Further, the number of the fiber particle forming apparatuses 12 may be three or more. A plurality of fiber particles 2 are formed by interlacing the fibers 3 into a granular shape. The fibers of a part of the fiber particles 2 may protrude toward the periphery. The fiber particles 2 from the second fiber particle forming device 12B enter the second accommodating tower 13B, and are then transported to the next step.

However, as the fiber particles 2, it is not limited to the fiber particles obtained by the above method. Fiber 2 can be made of fiber 3 in a suitable shape. Fiber particles. For example, the fiber ball disclosed in Patent Document 1 can be used as the fiber particle 2. The fiber particles 2 may be fiber balls.

The fiber particles 2 are conveyed to the fiber particle disposing device 14. The fiber particle disposing device 14 is a device that disposes the fiber particles 2 in a three-dimensional manner into a sheet shape. Since the fiber particles 2 are light, they can be transported by an air stream. If the fiber particles 2 are driven by the air flow, the air contacts the fiber particles 2, whereby the fiber particles 2 can be maintained in a state of particles while the fibers are easily protruded toward the periphery of the particles. Therefore, the fiber particles 2 are easily bonded.

The fiber arranging device 14 includes a arranging container 15 . In the configuration container 15, the gap 16 is provided at the lower portion. The gap 16 can be a groove-like gap. The gap 16 is formed to be elongated. In the example of Fig. 3, the gap 16 is formed by a plurality of rollers 17. In Fig. 3, two rollers 17a and a roller 17b which are a pair are depicted. The number of the rollers 17 may be three or more pairs. The plurality of rollers 17 are arranged in parallel. The direction in which the roller 17 extends can be the same as the width direction of the sheet of the formed fibrous particles 2. The gap 16 may be the same as the width direction of the sheet of the formed fibrous particles 2. Of course, the gap 16 can also follow the longitudinal direction of the sheet. At this time, the gap 16 can be set in plural. The gap 16 is formed in such a manner that the fiber particles 2 can pass. The roller 17a and the roller 17b are rotatable in opposite directions. In the example of Fig. 3, in the gap 16 between the two rollers 17, the roller 17 can be rotated (see a broken line arrow) so that the fiber particles 2 flow downward. The plurality of rollers 17 can have the properties of a feeder that can push the fiber particles 2 out. The fiber granules 2 can be pushed out by a feeder. If the gap 16 is provided, the fiber 2 can be prevented from staying That is, when the container 15 is placed and dropped, the fiber particles 2 can be easily arranged in a three-dimensional manner. Further, the roller 17 is an example of a feeder that passes the fiber particles 2 between the gaps 16. As the feeder, a feeder of another configuration may be used.

In the fiber arranging device 14, the fiber particles 2 enter the arrangement container 15 from above. At this time, the fiber 2 can be pushed by the air. The fiber particles 2 entering the configuration container 15 are dropped to the lower side due to the action of gravity. The fiber particles 2 dropped to the lower side reach the vicinity of the roller 17. Also, the fiber particles 2 will pass through the gap 16 and fall to the lower side. If passed through the gap 16, the fiber particles 2 can be equally dropped to the lower side. Therefore, the fiber particles 2 can be evenly arranged to form a body shape. If the roller 17 is rotated in a direction in which the fiber particles 2 are dropped to the lower side, the fiber particles 2 are more likely to fall. The fiber particles 2 passing through the gap 16 come out from the lower side of the arrangement container 15.

The gap 16 is preferably a size such that the fiber particles 2 having an average particle diameter are caught in the gap 16. When the width of the gap 16 is too wide and the fiber particles 2 pass through the gap 16 without remaining, there is a fear that the uniformity of the arrangement of the fiber particles 2 is deteriorated. On the other hand, if the width of the gap 16 is too narrow, there is a fear that the fiber particles 2 do not easily enter the gap 16. The fiber particles 2 can be caught by fibers protruding toward the periphery, or can be caught by physical forces such as electrostatic force. The width of the gap 16, that is, the size between the rolls 17, is preferably 50 to 200% of the average particle diameter of the fiber particles 2. By making the width of the gap 16 to this extent, the uniformity of the arrangement of the fiber particles 2 can be improved. The width of the gap 16 is more preferably 70 to 150% of the average particle diameter of the fiber 2

Here, it is preferable that a plurality of fiber particles 2 are accommodated first, and then a plurality of fiber particles 12 are output from the gap 16. When the fiber particles 2 are not accommodated, the fiber particles 2 are directly sent to the lower side by the air flow when they are sent from the pipe, and thus the fiber particles 2 cannot be uniformly disposed. However, if the fiber particles 2 are temporarily accommodated and then the fiber particles 2 are output from the gap 16, the fiber particles 2 can be easily discharged from the gap 16 in a stable amount to the outside of the arrangement container 15. The accommodation of the fibrous particles 2 can be carried out in the vicinity of the gap 16. For example, as shown in Fig. 3, if the roller 17 is provided, the fiber pellet 2 is temporarily accommodated on the roller 17. The fibrous particles 2 can be accommodated in the configuration container 15. The fiber particles 2 can also be accommodated above the gap 16. The fiber particles 2 can be stacked in the vertical direction. Further, among the accommodated fiber particles 2, the fiber particles 2 existing in the vicinity of the roller 17 rotate with the roller 17, and pass through the gap 16 and are driven downward. The portion of the configuration container 15 in which the fiber particles 2 are placed is defined as the accommodating portion 18. The accommodating portion 18 is located above the gap 16 and the roller 17. Further, the fiber particles 2 accommodated in the accommodating portion 18 can be advanced to the lower side. Thereby, the propulsive force is applied to allow the fiber particles 2 to easily pass through the gap 16. The push can be carried out by using air pressure or a push roller. The fiber particles 2 can be pushed out from the gap 16.

The plurality of fiber particles 2 that have come out of the arrangement container 15 are formed into a sheet shape and arranged in a three-dimensional manner. The plurality of fiber particles 2 that have moved to the lower side of the arrangement container 15 can be disposed approximately equally in the width direction and the thickness direction. Further, by the plurality of fiber particles 2 flowing, they can be arranged approximately evenly in the flow direction. a plurality of fibrous particles arranged in a three-dimensional manner 2, becoming a precursor of the fiber sheet 1. The plurality of fiber particles 2 arranged in a sheet shape in a three-dimensional manner is defined as a sheet-like fiber particle 2S.

Below the configuration container 15, it is preferable to provide the inclined portion 19. The inclined portion 19 can be formed by inclining a passage through which the fiber particles 2 flow. The inclined portion 19 can also be formed by tilting the board. By having the inclined portion 19, the flaky fiber particles 2S can flow while maintaining a three-dimensional shape. The flaky fiber particles 2S are continuously formed by flowing over the inclined portion 19 while flowing. The inclination angle of the inclined portion 19 can be appropriately adjusted to such an angle that the fiber particles 2 in the flaky fiber particles 2S are not dispersed, and the flaky fiber particles 2S are easily flowed downward. The inclined portion 19 may be made of, for example, metal.

In the flaky fiber particles 2S, the fibers protruding toward the periphery can be entangled. Thereby, the fiber sheet 1 with high adhesiveness can be formed easily. Further, the plurality of fiber particles 2 from the arrangement container 15, that is, the flaky fiber particles 2S, are three-dimensionally formed by intertwining fibers, but the connection between the particles is weak. Therefore, if the sheet-like fiber particles 2S are stretched, the fiber particles 2 are easily dispersed.

The flaky fiber particles 2S are preferably measured. The amount of fiber is stabilized by measuring the flaky fiber particles 2S. The weight per unit area of the sheet fiber particles 2S was measured by measurement. In the measurement of the flaky fiber particles 2S, a specific specification can be set. For example, if the weight falls within a specific range of the weight of the reference value (for example, ±10%), it is judged to be a good product, and if it is outside the range, it is determined to be a defective product. The fiber sheet 1 in which the fiber particles 2 are more uniformly arranged can be easily obtained by measurement. Measurement is in the fiber The configuration device 14 is implemented between the heating device 20. The measurement is preferably carried out while conveying the flaky fiber particles 2S. For example, the measuring instrument 22 is disposed below the passage through which the flaky fiber particles 2S flow, whereby the measurement can be continuously performed. The measuring instrument 22 can be disposed, for example, below the inclined portion 19. The measuring instrument 22 may be provided in the middle of the inclined portion 19. In Fig. 3, the state in which the sheet-like fibrous particles 2S are measured by the measuring instrument 22 is shown. Here, the fiber particles 2 in the flaky fiber particles 2S are not bonded, and can be easily dispersed. Therefore, when it is judged that it is a defective product, the flaky fiber particle 2 of this part can be taken out, and the fiber particle 2 is disperse|distributed, and it returns to the step which arrange|positions the fiber particle 2 in the sheet shape. Therefore, material waste can be saved. Further, it is preferable to carry out feedback control in such a manner that the flaky fiber particles 2S fall within a specific weight range by measurement, and the feedback control can adjust the supply amount of the fiber particles 2 in the fiber particle arranging device 14. . For example, when the weight of the flaky fiber particles 2S is smaller than a specific weight, the amount of the fiber particles 2 from the fiber granule device 14 is increased, and when the weight of the flaky fiber particles 2S is larger than a specific weight, the fiber is reduced from the fiber. The amount of fiber particles 2 coming out of the granulating device 14. If the feedback control is carried out in this way, the uniformity in the transport direction is improved, and the fiber sheet 1 having higher uniformity can be obtained.

The flaky fiber particles 2S are sent to the heating device 20. The flaky fiber particles 2S can be transported by being pushed on the passage or by a conveyor. The heating device 20 heats the flaky fiber particles 2S to a temperature at which the heat-fusible fibers exhibit weldability. Thereby, the fibers are bonded by the heat-fusible fibers, and thus the plurality of fiber particles 2 are bonded and formed into a sheet shape. The heating device 20 can face the sheet The fiber particles 2S are heated to pass the sheet-like fiber particles 2S through the gap formed by the rolls 21. The thickness of the fiber sheet 1 can be adjusted in accordance with the size of the gap formed by the roller 21. The size of the gap formed by the roller 21 can be formed by the opposing rollers 21 or by the roller 21 and the conveyor. In the third figure, an example of the opposing roller 21 is shown. However, since the fiber particles 2 are soft, it is preferable that the pressing force by the roller 21 is weak. Further, the flaky fiber particles 2S can be pressurized, and in this case, the thickness of the fiber sheet 1 can be adjusted by the space formed by the pressurization. Further, the flaky fiber particles 2S can be heated in such a manner that no roller 21 or no pressure is applied without applying a physical force. In this manner, the plurality of fiber particles 2 arranged in a three-dimensional manner are heated, and the plurality of fiber particles 2 are bonded by the heat-fusible fibers. The bonding can be carried out by a portion in which the fibers 3a protruding toward the periphery are in contact with other fibers. The fibers 3 in the fiber particles 2 can be bonded to each other. If the contacted fibers 3 contain heat-fusible fibers, they can be bonded. The fiber sheet 1 is formed by stereoscopic molding as described above.

When the fiber sheet 1 is continuously formed, the fiber sheet 1 can be adjusted to an appropriate shape. The fiber sheet 1 can be taken up or cut. For example, in the case of a relatively thin sheet, the fiber sheet 1 can be fed out and taken up. In Fig. 3, a roll-shaped fiber sheet 1R is drawn as the wound fiber sheet 1. The roll-shaped fiber sheet 1R can be used for applications requiring deformability or flexibility, such as clothes and the like. In the fiber sheet 1, the fiber particles 2 are firmly bonded, and therefore, even if the winding is performed, the fiber particles 2 are not easily peeled off. If the fiber sheet 1 can be taken up, the productivity is improved. also, In the case of a relatively thick sheet, the fiber sheet 1 can be cut to an appropriate size. The cut fiber sheet 1 may be in the form of a plate. In Fig. 3, a sheet-like fiber sheet 1B is drawn as the cut fiber sheet 1. The platy fiber sheet 1B can be used, for example, for a core material of a mattress or the like. In the fiber sheet 1, the fiber particles 2 are firmly bonded, and therefore, even if the cutting is performed, the fiber particles 2 are not easily peeled off. If the fiber sheet 1 is in the form of a plate, the operability is improved.

In the method for producing the fiber sheet 1, the fiber sheet 1 can be continuously produced from the original cotton 10. Improve production efficiency through continuous manufacturing. The opened fiber 3 can be continuously formed from the original cotton 10. The fiber particles 2 can be continuously formed from the fibers 3. The flaky fiber particles 2S can be continuously formed from the fiber particles 2. The fiber sheet 1 can be continuously formed from the flaky fiber particles 2S. In this way, the steps can be continuously performed and carried out, so that continuous production from upstream to downstream can be performed. Of course, the steps can be carried out separately. Even in this case, continuous processing is performed in each step, thereby increasing production efficiency.

A further preferred aspect of the fibrous particle arranging device is illustrated by Figure 4. Fig. 4 is a schematic configuration diagram showing the fiber particle arranging device 50. Fig. 4 is composed of Fig. 4A and Fig. 4B. Fig. 4A is a side view, and Fig. 4B is a front view. The fiber particle disposing device 50 described below can be replaced with the fiber particle disposing device 14 described above. Therefore, in the fourth drawing, the configuration corresponding to the above-described configuration is denoted by the same reference numerals in parentheses. For example, it is described as "fibrous particle arranging device 50 (14)". Furthermore, in Fig. 4, the air flow is indicated by a blank arrow. A thick arrow with a diagonal line pattern indicates the flow of the fiber particles, and an arrow indicates the action of the mechanical parts (rollers, etc.).

The fiber particle disposing device 50 is a device that arranges a plurality of fiber particles 2 in a three-dimensional manner to have a sheet shape. The fiber arranging device 50 includes a supply duct 51, an exhaust duct 52, a storage unit 53, a supply roller 55, a distribution roller 56, a accommodating portion 57, a transport roller 60, an ejecting plate 61, a fan 62, a control unit 63, and And the input/output unit 64.

The supply duct 51 is a passage of air that drives the fiber particles 2 sent from the upstream accommodating tower 13 (see Fig. 3). The exhaust duct 52 is a passage of air that exhausts air flowing out of the supply duct 51. As the entire fiber particle disposing device 50, air flows in from the supply duct 51 and flows out in the exhaust duct 52. However, a portion of the air will flow to the dispensing roller 56. The fiber particles 2 that have entered the supply duct 51 are driven downward and stored in the storage portion 53. The storage portion 53 can stabilize the supply amount of the fiber particles 2 by temporarily storing (accommodating) the fiber particles 2. Further, the storage portion 53 can cut off the air pressure of the supply duct 51 without adversely affecting the three-dimensional arrangement of the fiber particles 2. An upper air discharge port 54 is provided in the storage portion 53. The upper air discharge port 54, for example, is constituted by an apertured plate. By having the upper air discharge port 54, the supplied air can be smoothly vented, and the inside of the apparatus can be prevented from being subjected to excessive pressure.

The fiber particles 2 that have entered the storage portion 53 are sent to the downstream by the supply roller 55. By the rotation of the supply roller 55, the fiber particles 2 flow toward the dispensing roller 56. The supply roller 55 and the control unit 63 are electrically connected. The rotation speed of the supply roller 55 can be adjusted by the control of the control unit 63. Control department 63 can be constructed by a circuit. The amount of the fiber particles 2 fed from the supply roller 55 is adjusted by changing the rotational speed of the supply roller 55. When the rotation speed is increased, the amount of the fiber particles 2 to be fed is increased. Conversely, when the rotation speed is slowed, the amount of the fiber particles 2 to be fed is reduced. A scraping portion 55a may be provided in the supply roller 55. The scraping portion 55a scrapes off the fiber pellet 2 and sends it out. The scraping portion 55a may be constituted by a zigzag protruding portion provided on the outer edge of the supply roller 55. Further, the scraping portion 55a can be formed, for example, by providing a wire on the supply roller 55.

The distribution roller 56 has a performance in which a plurality of fiber particles 2 fed from the supply roller 55 are distributed along the width direction of the fiber sheet 1. The width direction of the fiber sheet 1 is the same as the axial direction (longitudinal direction) of the distribution roller 56. The dispensing roller 56 can be a roller that rotates at a fixed speed. The diameter of the dispensing roller 56 can be larger than the diameter of the supply roller 55. By the distribution roller 56, the fiber particles 2 are distributed in the axial direction of the distribution roller 56, and the fiber particles 2 can be uniformly disposed. The distribution roller 56 has a plurality of protruding bars 56a. The plurality of projecting bars 56a are disposed at equal intervals in the circumferential direction at the outer edge of the distribution roller 56 (Fig. 4A), and are further disposed at equal intervals in the axial direction of the distributing roller 56 (Fig. 4B). By providing the protruding bars 56a, the amount of the fiber particles 2 in the direction along the axial direction of the distributing roller 56 is more uniform. The fiber particles 2 dispensed by the distribution roller 56 easily flow to a portion where the flow resistance is low, and thus automatically face the portion of the accommodating portion 57 where the amount of the fiber granules 2 is small.

The fiber particles 2 passing through the distribution roller 56 enter the accommodating portion 57. The accommodating portion 57 accommodates the fiber particles 2 sent from the dispensing roller 56. The accommodating portion 57 corresponds to the accommodating portion 18 of FIG. By temporarily accommodating the fiber particles 2 in the accommodating portion 57, the fiber particles 2 can be stably disposed. A lower air discharge port 58 is provided in the accommodating portion 57. The lower air discharge port 58 is constituted, for example, by an apertured plate. By having the lower air discharge port 58, the air flowing into the accommodating portion 57 can be smoothly vented, and the accommodating portion 57 can be prevented from being subjected to excessive pressure. The lower air discharge port 58 is coupled to the internal air passage 59, and thus the air flows to the internal air passage 59.

The fiber arranging device 50 further includes a sheet width adjuster 66 as shown in FIG. 4B. The sheet width adjuster 66 is disposed in the accommodating portion 57. By having the sheet width adjuster 66, it is easier to adjust the width of the fiber sheet 1. The sheet width adjuster 66 is composed of a pair of sheet width adjusting portions 66a. The pair of sheet width adjusting portions 66a can be moved closer to or away from each other. When the pair of sheet width adjusting portions 66a are close to each other, the width of the fiber sheet 1 can be made small, and when the pair of sheet width adjusting portions 66a are separated, the width of the fiber sheet 1 can be made large. The sheet width adjuster 66 can be configured such that the space of the accommodating portion 57 is gradually narrowed from the upstream toward the downstream.

The fiber particles 2 accommodated in the accommodating portion 57 are transported from the accommodating portion 57 through a pair of the transport rollers 60. The carry-out roller 60 corresponds to the roller 17 of Fig. 3. A gap 16 similar to that described above is provided between the pair of carry-out rolls 60. Therefore, the fiber particles 2 can be disposed in a three-dimensional manner efficiently and satisfactorily. In the fiber particle arrangement 50, the gap 16 can define an approximate thickness of the fiber sheet 1. The gap 16 can be set, for example, in the range of 5 to 100 mm.

Here, the fiber particle disposing device 50 is provided with an internal air passage 59 that circulates air. The internal air passage 59 is coupled to both the upstream side and the downstream side of the accommodating portion 57. A fan 62 is provided in the internal air passage 59. The air flow can be created in the internal air passage 59 by the fan 62. The fan 62 is electrically connected to the control unit 63. The control unit 63 can control the rotation of the fan 62. By the rotation of the fan 62, the flow velocity of the air in the internal air passage 59 is changed. Thereby, the pressure in the accommodating portion 57 also changes. In the internal air passage 59, generally, the air that has flowed out from the accommodating portion 57 through the lower air discharge port 58 rises, and the air can enter the upper portion of the accommodating portion 57 (below the distribution roller 56).

The control unit 63 can control the amount of the fiber particles 2 of the accommodating portion 57. The control unit 63 is configured to be able to adjust the pressure of the accommodating portion 57 to a specific pressure. The control unit 63 is electrically connected to the supply roller 55, and can control the rotational speed of the supply roller 55. Further, the control unit 63 is electrically connected to the pressure sensor 57 and the fan 62, and the pressure sensor 57 is disposed in the accommodating portion 57. Thereby, the control unit 63 can control the fan 62 such that the pressure of the accommodating portion 57 is a specific value (set value) in accordance with the pressure detected by the pressure sensor 65. Moreover, the control unit 63 is electrically connected to the carry-out roller 60, and can control the rotational speed of the carry-out roller 60. Thereby, the amount of the fiber particles 2 can be adjusted, and the arrangement of the fiber particles 2 can be favorably performed. Alternatively, the take-up roller 60 can be configured to be freely rotatable. At this time, the fiber particles 2 can be pushed downward by the air pressure of the accommodating portion 57 to pass between the rollers 60. Rotation speed of the carry-out roller 60 The degree can be monitored by the control unit 63. In this way, based on the pressure information and the rotational speed information, the control unit 63 can adjust the rotational speed of the supply roller 55 and the pressure of the accommodating portion 57, and adjust the amount of the fiber particles 2 to be placed. For example, when the pressure of the accommodating portion 57 is excessively high, the control portion 63 can control the rotation speed of the supply roller 55 to be slow, so that the excess fiber particles 2 do not enter the accommodating portion 57. Thereby, the pressure of the accommodating portion 57 is lowered to return to an appropriate value. In addition, when the rotation speed of the carry-out roller 60 is increased, that is, the amount of the fiber particles 2 is increased, the control unit 63 can control the rotation speed of the supply roller 55 to increase the fiber 2 supply. To the accommodating portion 57. Thereby, it is possible to suppress the lack of the fiber particles 2 in the accommodating portion 57. In this way, the control unit 63 can cause the appropriate amount of the fiber particles 2 to enter the accommodating portion 57 and be discharged from the accommodating portion 57. Therefore, the arrangement of the granules 2 can be satisfactorily performed.

The input/output unit 64 is a part that exchanges information between the outside and the inside. The input/output unit 64 includes an input unit and an output unit. The input unit is composed of a switch, a button, a knob, a channel, and the like. The output unit is composed of a meter, a digital display, a display, and the like. For example, by inputting a specific rotation speed, the supply roller 55 rotates at the rotation speed, and the fiber pellets 2 are sent downstream.

The fiber particles 2 sent out from the take-up roll 60 become sheet-like fiber particles 2S and are carried on the carry-out plate 61. The carry-out plate 61 has an inclined portion 19. The flaky fiber particles 2S are transported to the heating device 20 (see Fig. 3).

As described above, the flaky fiber particles 2S are preferably measured by the measuring instrument 22 (refer to Fig. 3). And, preferably, by measuring Feedback control is performed in such a manner that the flaky fiber particles 2S fall within a specific weight range, and the feedback control can adjust the supply amount of the fiber particles 2 in the fiber arranging device 50. For example, when the weight of the flaky fiber particles 2S is smaller than a specific weight, the rotation speed of the supply roller 55 and/or the carry-out roller 60 can be increased to increase the amount of the fiber particles 2 emerging from the fiber granule device 50. Further, when the weight of the flaky fiber particles 2S is larger than a specific weight, the rotation speed of the supply roller 55 and/or the delivery roller 60 can be lowered to reduce the amount of the fiber particles 2 from the fiber granule device 50. By performing feedback control, it is possible to obtain the fiber sheet 1 having higher uniformity.

In this manner, the fiber arranging device 50 includes at least a storage portion 53 that accommodates a plurality of fiber particles 2, a supply roller 55 that feeds the stored plurality of fiber particles 2, and a distribution roller 56 that is along the fiber sheet. A plurality of fiber granules 2 fed from the supply roller 55 are distributed in the width direction; a accommodating portion 57 accommodating a plurality of fiber granules 2 fed from the distribution roller 56; and a pair of delivery rollers 60 are carried out for accommodating The plurality of fiber particles 2 accommodated in the portion 57. Further, the gap 16 is provided between the pair of carry-out rollers 60. Therefore, the fiber particles 2 can be made uniform and arranged, and a good fiber sheet can be formed.

The fiber sheet 1 is not a woven fabric, and in this sense, it can be considered to belong to the category of non-woven fabric, but the fiber sheet 1 has properties and states completely different from those of the conventional nonwoven fabric. The fiber sheet 1 has a lot of voids. The fiber sheet 1 has a granular portion (granular portion 2A) and a cotton-like portion (small portion 2B), and these portions are adhered by adhesion. Therefore, such as As described above, it is possible to obtain a unique effect that cannot be imagined by the past fibers.

The fiber sheet 1 can be used for bedding, cushions, and the like. For example, bedding can be provided by using the fiber sheet 1 as a core material and mounting a cover. The fiber sheet 1 is preferably pressure-resistant and dispersible. Further, the fiber sheet 1 can be used for clothing. Further, the fiber sheet 1 has a structure in which the fiber particles 2 are provided inside, and therefore, various developments can be performed. For example, it can be used for a seat cushion of a vehicle such as a car, a train, a train, a ship, or an airplane. The transportation means requires a lighter material as possible, and the above-mentioned fiber sheet 1 is light and strong, and thus is suitable. Further, for example, the fiber sheet 1 can be placed in water, placed in a plant seed or the like, and used for agricultural purposes such as hydroponic cultivation. Further, for example, the fiber sheet 1 can be used for medical use. Moreover, since the fiber sheet 1 is heat-insulating and excellent in sound absorbing property, it can be used, for example, as a building material.

(Example)

Fibrous granules are produced from polyester staple fibers in accordance with the methods described above. The fiber granules are arranged in a sheet form and heated to prepare a fiber sheet.

Figure 5A is a photograph of fiber particles. Figure 5B is a photograph of a fiber sheet. As shown in Fig. 5B, the fiber sheet has a plurality of fiber particles. It was confirmed that the fiber sheet can exhibit a unique elastic force which is different from a sheet which is only intertwined by the fibers in a three-dimensional manner.

Here, in the production of the above-mentioned fiber granules, examples of the fiber particles having high resilience (particle example 1) and examples of low-rebound fiber particles (particle example 2) are used as the method of the past. Examples of the produced fiber particles (Particle Example 3), examples of fiber particles available on the market (Particle examples) 4) Four kinds of fiber particles, and the structure (the state of the fibers of the fiber particles) is compared by the following method.

First, 20 fiber granules were arbitrarily selected. One of the fiber particles was placed on a white resin plate of the sample stage, and a slide glass was placed on the fiber particles. Further, a white resin plate is used to diffuse transmitted light. The fiber particles were irradiated with light, and a microscope (VHX-900 manufactured by Keynes Co., Ltd.) was used, and a photograph of the fiber particles was taken with a setting of transmitted light at a magnification of 20 times, and then the image was stored. This image storage was performed for 20 fiber pellets. Then, the image of the fiber particles is grayed out by image processing. The grayscaled image is nested in a matrix of two-dimensional squares, and the values (grayscale values) determined by the gray shading of 256 steps from black 0 to white 255 are assigned to the respective cells. For the assigned gray scale value, the standard deviation of the average of the row and the column is obtained from the average of the row and the column, and the average value of the standard deviation is further obtained.

Table 1 shows the results of the fiber particles of the particle examples 1 to 4 obtained by the above method. Fig. 6 is a graph showing the standard deviation of the gray scale values of the particle examples of the four types of fiber particles. The smaller the standard deviation, the more uniformly the fibers in the fiber granules are disposed. The standard deviation of the particle examples 1, 2 is 9 or less, and is a uniform fiber particle. On the other hand, the standard deviation of the particle example 3 exceeded 9, and the uniformity was worse than the particle examples 1, 2. Further, the standard deviation of the particle example 4 exceeded 11, so the uniformity was further inferior. The more uniform the fiber granules, the better the elasticity of the fiber flakes. The fiber sheet was produced from four kinds of fiber particles, and the fiber sheets of the particle examples 1 and 2 were more excellent in elasticity than the fiber sheets of the particle examples 3 and 4.

Therefore, it is preferable that the fiber particles are arbitrarily selected by a specific number (for example, 20), and the light is irradiated and the image is taken, and then the image is analyzed in gray to adjust the standard deviation of the gray scale value. It is 9 or less. again The smaller the standard deviation is, the lower the lower limit of the grayscale value is ideally 0, but it can be 1 in consideration of reality.

Fig. 7 is an example of a photograph of the above four types of fiber particles. Fig. 7 is composed of Fig. 7A to Fig. 7D. Fig. 7A shows the fiber particles (2p) of the particle example 1. Fig. 7B shows the fiber particles (2q) of the particle example 2. Fig. 7C shows the fiber particles (2r) of the particle example 3. Fig. 7D shows the fiber particles (2s) of the particle example 4. The fibers of the central portion of the fiber particles of the particle examples 1, 2 were more dense than the fiber particles of the particle example 4. Therefore, in the particle examples 1 and 2, the fiber particles have a core portion in which the fibers are closely intertwined. The fiber pellet having the core can be said to have a structure such as a golf ball having a core inside, and a structure such as a table tennis ball having a hollow inside.

1‧‧‧Fiber flakes

2‧‧‧ fiber particles

2A‧‧‧Grain

2B‧‧‧Mous

3, 3a‧‧‧ fiber

Claims (6)

A fiber sheet having a plurality of fiber granules formed by fiber interlacing, and the plurality of fiber granules are entangled in a three-dimensional manner by fibers protruding toward the periphery, the plurality of fibers The particles are bonded by the heat-fusible fibers contained in the plurality of fiber particles; and the fiber sheet has a granular portion formed of the fiber particles, and a fibrous portion disposed in the granular portion The ratio of the number of the above-mentioned fiber granules is 10 to 100,000 in terms of a sheet having a length of 100 mm, a width of 100 mm, and a thickness of 10 mm. The fiber sheet according to claim 1, wherein the fiber particles have an average particle diameter in the range of 1 to 50 mm. The fiber sheet according to claim 1, wherein the thickness of the fiber sheet is in the range of 5 to 100 mm. The fiber sheet according to any one of claims 1 to 3, wherein the fiber particle has a core portion which is closely intertwined with the fibers. A method for producing a fiber sheet, comprising the steps of: interlacing fibers into granules to form a plurality of fiber granules; and arranging the plurality of fiber granules in a three-dimensional manner to form a flaky shape; Heating the plurality of fiber particles arranged in a three-dimensional manner, and bonding the plurality of fiber particles by the heat-fusible fibers contained in the plurality of fiber particles; wherein the plurality of fiber particles are The step of arranging into a sheet shape in a three-dimensional manner includes the steps of: accommodating the plurality of fiber particles; and outputting the plurality of fiber particles from the gap. The method for producing a fiber sheet according to claim 5, wherein the step of disposing the plurality of fiber particles in a three-dimensional manner into a sheet shape is carried out by a fiber particle disposing device, wherein the fiber particle disposing device comprises: a storage portion that stores the plurality of fiber particles; a supply roller that feeds the plurality of stored fiber particles; and a distribution roller that distributes the plurality of fiber particles sent from the supply roller along a width direction of the fiber sheet a accommodating portion accommodating the plurality of the plurality of fiber particles fed from the distribution roller; and a pair of transporting rollers that carry out the plurality of fiber particles accommodated in the accommodating portion; and the gap is set Between the aforementioned pair of take-up rolls.